Faculty of engineering

Mechanical Engineering Dept.

Machine Tools Design

Instructors:
Prof. Dr. Abdelrhman Moussa
Prof. Dr. Mohamed Fekry
Dr. Ahmed Mhroos
Dr. Mohamed Abdallah Bhlol
 Faculty of engineering
Mechanical Engineering Dept.

Machine Tools Design

Chapter 2
Mechanical transmission
elements

Dr. Mohamed Abdallah Bhlol

An introduction to machine tools

Mechanical transmission and its elements

Elementary transmissions for transmitting rotary

motion

Transformation of rotary motion into reciprocating

motion

Reversing mechanisms
An introduction to machine tools
“ A machine tool is a machine for making articles of a
given shape, size and accuracy by removing metal from
workpiece in form of chips”.

Any machine tool should satisfy the following

requirements:

High productivity,
Ability to provide the required accuracy of shape and
size and also necessary surface finish,
Simplicity of design, safety and convenience controls,
Good appearance,
Low cost of manufacturing and operation,
Low cost of maintenance, and
Good durability
An introduction to machine tools
Classification of machine tools
Machine tools can be classified by different criteria as
follows:
1. According to degree of automation
• Machine tools with manual control
• Semi-automatic machine tools
• Automatic machine tools

2. According to degree of specialization

• General purpose or universal machine tools (used to
work a wide range of parts)
• Specialized or single purpose machine tools (used for
articles similar in shape but different in size)
• Limited purpose machine tools (capable of a narrow
range of operations on a wide varity of workpieces)
An introduction to machine tools
• Special machine tools (perform a single operation on
workpieces of a particular shape and size)

3. According to weight
• Light machine tools up to one ton
• Medium machine tools up to 10 tons, and
• Heavy machine tools over 10 tons

4. According to accuracy
• Machines of normal accuracy, covering the majority of
general purpose machine tools
• Machines of higher accuracy
• Precision machines
• High precision machines
• Super high precision machines
Mechanical transmission and its elements
Mechanical transmission:
Mechanical transmission is employed for transmitting
rotary as well as translatory motion to the operative
element.

This transmission can provide both stepped and

stepless regulation of speed and feed rates.

Stepless regulation is achieved through special

devices called variators.

A mechanical transmission that provides for stepped

regulation is made up of elementary drives and
mechanisms.
Mechanical transmission and its elements
Mechanical transmission:
Classification of mechanical transmission:
1. Elementary transmissions that transfer rotation

2. Elementary transmissions that transform rotary

motion into translatory motion

3. Devices for intermittent motion

4. Reversing and differential mechanisms

5. Special mechanisms and devices

6. Coupling and clutches

Mechanical transmission and its elements
Elementary transmissions for transmitting rotary motion:
a) Gear drive:
Gears are machine elements that
transmit rotary motion and power
between two shafts by meshing
without any slip.

They are positive in their action

(exact speed ratios), a feature that
most of the machine tools require.

In any pair of gears, the smaller one

is called pinion and the larger one is
called gear
Mechanical transmission and its elements
Elementary transmissions for transmitting rotary motion:
a) Gear drive:

When pinion is the driver, it

results in step down drive in
which the output speed
decreases and the torque
increases.

When the gear is the driver, it

results in step up drive in
which the output speed
increases and the torque
decreases.
Mechanical transmission and its elements

Gears can be classified

as the following:

a) Spur gears
b) Helical gears
c) Double helical
gears
d) Internal gears
e) Rack and pinion
f) Straight bevel
gears
g) Spiral bevel gears
h) Hypoid bevel gears
i) Worm gears
j) Spiral gears
 Classification of gears
Spur gears
used to transmit motion between
parallel shafts or between a shaft and a
rack.

Spur gears have their teeth parallel to

the axis of rotation.

They are simple in construction and

easy to manufacture.

Suitable for low to medium speed

application.
 Classification of gears
Helical gears
Transmit motion between parallel
shafts or between a shaft and a rack.

The teeth lie along a helix at an angle to

the shaft

For the same width, their teeth are

longer than spur gears and have higher
load carrying capacity.

Their contact ratio is higher than spur

gears and they operate smoother and
quieter than spur gears.

They are recommended for very high

speeds and loads.
 Classification of gears
Double helical gears

Double helical or Herringbone gears

used for transmitting power between
two parallel shafts.

They have opposing helical teeth

with or without a gap depending on the
manufacturing method.

Two axial thrusts oppose each other

and gets canceled.

Their load capacity is very high,

manufacturing difficulty makes them
costlier than single helical gear.
 Classification of gears
Internal gears
Internal gears are used for transmitting
power between two parallel shafts.

The meshing pinion and gear are

running in the same direction.

Provides more compact drives and

large contact ratio compared to external
gears

Their main applications are as follows:

-Rear drives for heavy vehicles.
-Planetary gears.
-Toothed clutches.
-Speed-reducing devices.
-Compact design requirements.
Classification of gears
Straight bevel gears
 These gears transmit rotary motion
between two perpendicular shafts( non-
parallel but intersecting).

limited to low speed drives

Used where noise is not important.

Operate at high efficiencies of 98% or

better.
 Classification of gears
Spiral bevel gears
Are also used for transmitting power
between intersecting shafts.

Because of the spiral tooth, the

contact length is more and contact ratio
is more than straight bevel gear.

They operate smoother than straight

bevel gears and have higher load
capacity.

Their efficiency is slightly lower than

straight bevel gear
 Classification of gears
Hypoid bevel gears
 These gears are also used for
right angle drive in which the axes
do not intersect.

Their efficiency is lower than other

two types of bevel gears.

These gears are widely used in

current day automobile drive line
power transmission.
 Classification of gears
Worm gears
 Worm and worm gear pair consists of
a worm, which is very similar to a screw
and a worm gear.

High reduction ratios

Used in indexing heads of milling

machines and in hobbing machines.
 Classification of gears
Spiral gears
Spiral gears are also known as
crossed helical gears. They have
high helix angle

They transmit power between two

non-intersecting non-parallel shafts.

Useful where shafts must rotate at

an angle to each other.
Mechanical transmission and its elements
Elementary transmissions for transmitting rotary motion:
a) Gear drive:
Transmission Ratio (i) Calculation:
 Transmission ratio is the ratio between output speed of the
driven shaft to input speed of the drive shaft.

 or the ratio between no. of teeth of drive gear to no. of

teeth of driven gear.

In a gear drives, the rotational speed of the driven shaft is

calculated from:
Z1 n2 Z1 D1
n 2  n1 . i   
Z2 n1 Z2 D2
Mechanical transmission and its elements
a) Gear drive:
 Where:
 n1 = rotational speed of the driving shaft , r.p.m
n2 = rotational speed of the driven shaft , r.p.m
 Z1 = number of teeth of the driving gear
 Z2 = number of teeth of the driving gear
For worm and worm gear:
n2 K
n 2  n1 .
K i  
Z n1 Z
 Where:
 n1 = rotational speed of the worm, r.p.m
n2 = rotational speed of the worm gear, r.p.m
 Z = number of teeth of the worm gear
 K= number of threads of the worm (K = 1 for single thread)
Mechanical transmission and its elements
a) Gear drive:
In general the transmission ratio of gear drive may be >1
(speed increase)

or <1 (speed reduction),

except the worm-worm gear transmission which always

has a transmission ratio < 1.
Mechanical transmission and its elements
Elementary transmissions for transmitting rotary motion:
b) Belt drive:
The belt drive is used for
transmitting rotation between shafts
that are located at a considerable
distance from each other.

It is distinguished by smooth

rotation but slip is the main problem.

Belt transmission can be employed

for transmitting rotation between
parallel and skewed shafts.

In machine tool drives flat, V-shaped

and round belts are used.
Mechanical transmission and its elements
Elementary transmissions for transmitting rotary motion:
b) Belt drive:
Mechanical transmission and its elements
Elementary transmissions for transmitting rotary motion:
b) Belt drive:
Transmission Ratio Calculation:
The rotational speed of the
driven shaft in the belt drive is
calculated from the following
relationship:
D1
n 2  n1 . .C f
D2

n 2 D1
i  .C f
n1 D 2
Mechanical transmission and its elements
Elementary transmissions for transmitting rotary motion:
b) Belt drive:

 Where:
 n1 = rotational speed of the driving shaft , r.p.m
n2 = rotational speed of the driven shaft , r.p.m
 D1 = diameter of the driving pulley
 D2 = diameter of the driving pulley
 Cf = slip factor
Mechanical transmission and its elements
Elementary transmissions for transmitting rotary motion:
c) Chain drive:
The chain drive is employed for
transmitting rotation only between
parallel shafts that are located at a
considerable distance.

The chain transmission consists of a

driving sprocket, driven sprocket and
chain.

Chain transmission is used in

machine tools when it is essential to
keep dimension of the drive within
reasonable limits and also ensure
transmission without slip.
Mechanical transmission and its elements
Elementary transmissions for transmitting rotary motion:
c) Chain drive:
Transmission Ratio Calculation:
The rotational speed of the
driven shaft in the chain drive is
calculated from the following Z2
relationship: n2
Z1
Z1
n 2  n1 .
Z2 n1

n2 Z1 D1
i   
n1 Z2 D2
Mechanical transmission and its elements
Elementary transmissions that transform rotary motion
into translatory motion

These elementary transmissions are used in feed

mechanisms of most of the machine tools and also in the
drive of machine tools having a reciprocating primary
cutting motion.
Mechanisms used to transform rotary motion into linear
motion are:

The slider crank mechanism

Cam mechanism
Quick-return mechanism (shaper mechanism)
Rack and pinion mechanism
Screw and nut mechanism
Mechanical transmission and its elements
Elementary transmissions that transform rotary motion
into translatory motion

a) Slider crank mechanism:

The mechanism consists of a
crank, connecting rod and slider

Slider crank mechanism is

used only in machine tools with
small strokes (<300mm).
Mechanical transmission and its elements
Elementary transmissions that transform rotary motion
into translatory motion

b) Cam mechanism:
The mechanism consists
of a cam and a follower.

It generally used in

automatic machine tools
for mass production of
components.
Mechanical transmission and its elements
Elementary transmissions that transform rotary motion
into translatory motion

c) Quick-return mechanism (shaper mechanism):

The mechanism is
used in shaper
machine in cutting
and return strokes.
Mechanical transmission and its elements
Elementary transmissions that transform rotary motion
into translatory motion

d) Rack and pinion

 A rack is a gear whose pitch
diameter is infinite, resulting in a
straight line pitch circle.

Used to convert rotary motion to

straight line motion.

The tooth can be spur or helical

 Used in machine tools (drilling

machine and carriage of engine
lathe).
Mechanical transmission and its elements
Elementary transmissions that transform rotary motion
into translatory motion

d) Rack and pinion

 The linear velocity of the rack:

V Rack  p.Z .no

 Where:
 VRack = linear velocity of rack, mm/min
no = rotational speed of the pinion, r.p.m
 Z = no. of teeth of pinion
 p = pitch (mm)
Mechanical transmission and its elements
Elementary transmissions that transform rotary motion
into translatory motion
e) Nut and screw transmission

 The screw and nut

mechanism have a
trapezoidal thread. When
the screw, fixed axially, is
rotated, the nut moves
along the screw axis.

The direction of
movement can be reversed
by reversing the rotation of
the screw.
Mechanical transmission and its elements
Elementary transmissions that transform rotary motion
into translatory motion
e) Nut and screw transmission

 The linear velocity of the nut:

V nut p.K .n o
 Where:
 Vnut = linear velocity of nut, mm/min
no = rotational speed of the screw, r.p.m
 K = no. of threads or starts of the thread
 p = pitch of the thread (mm)
Mechanical transmission and its elements
Reversing mechanisms

 reversing mechanisms are used for changing the

direction of motion of the operative member.

Reversing is accomplished generally through spur

and helical gears or bevel gears.

It can used also jaw clutches.

Reversing mechanisms can be done for parallel

shafts and perpendicular shafts.
Mechanical transmission and its elements
Reversing mechanisms

a) Reversing mechanisms for parallel shafts

Using sliding gears

Using clutches
Mechanical transmission and its elements
Reversing mechanisms

b) Reversing mechanisms for perpendicular shafts

Using sliding gears Using clutches